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Splines add strength and style MORE TABLESAW MAGIC A slot-cutting jig makes it easy to run the assembled box over the blade at a perfect 45° angle. Front support, ¾ in. thick by 4¾ in. wide by 7½ in. long Rear support, ¾ in. thick by 4 in. wide by 7½ in. long Jig rides in miter slot. Fence, 33 Story stick dials in setup. Use a pencil to mark the slot locations on one corner of the box, then transfer the locations from the box to a thin, narrow stick. After that, use the stick to position a stop block on the jig. ⁄8 in. wide by 18 in. long, thicknessed to ride in miter slot Box Jig 1⁄8 in. Cut the slots. With the jig riding in the miter slot, make the first cut. Slot all four corners before moving the stop block for the next spline location. four flat sides transform into a box. To me, it’s the magic moment in box making. Now add more tape, as needed, to pull each of the corners tight. Check to make sure the box is square and that each edge is perfectly aligned. Also make sure the top panel and the bottom are centered in the sides. Let the glue dry overnight. Another simple sled for the splines Splines add strength and they look good, too. To cut the slots for the splines, I use the tablesaw with a rip blade that cuts a 1⁄8-in.wide kerf. This blade produces a kerf with a flat bottom that fits the square shape of the splines better than the shallow V-shape you get from typical crosscut or combination blades. I use a jig to support the box at 45° to the table. To create the most glue area for the splines, set the blade to a height that cuts the slot just short of the inside corner of the box. With the slots cut, you can move along to making the miter splines. To make the spline stock, I simply thickness-plane mate- rial down to the width required and then use the tablesaw to rip 1⁄8-in.-thick slices from the stock. I precut the spline stock to approximate size. This eliminates having to use a saw to trim the splines after the glue dries. Add a coat of glue to each spline and slot, then slip in the splines. Make sure that each one is fully seated at the bottom of the slot. A few www.finewoodworking.com SEPTEMBER/OCTOBER 2008 53 Slip in the splines. After planing the spline stock to fit and cutting out little triangles, add glue to the slots and splines and slide them into place. Sand the splines flush. Stowe uses a stationary beltsander to quickly sand the splines flush to the sides of the box. A block plane would also work.